Method for making fuel cell module having curved membrane electrode assembly

ABSTRACT

The disclosure relates to a method for making fuel cell system. The fuel cell system includes a fuel cell module curved to form a chamber. The fuel cell module includes a container having a number of through holes and a membrane electrode assembly located on the container and cover the number of through holes. The membrane electrode assembly includes a proton exchange membrane having a first surface and a second surface opposite to the first surface, a cathode electrode located on the first surface and an anode electrode located on the second surface. A fuel cell module is at least partially immerged in the fuel and the oxidizing gas is supplied in to the chamber of the fuel cell module.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims all benefits accruing under 35 U.S.C. § 119 fromChina Patent Application No. 201510281412.1, filed on May 28, 2015, inthe China Intellectual Property Office, disclosure of which isincorporated herein by reference.

FIELD

The subject matter herein generally relates to fuel cell modules andfuel cell systems using the same.

BACKGROUND

Fuel cells can generally be classified into alkaline, solid oxide, andproton exchange membrane fuel cells. The proton exchange membrane fuelcell has received increasingly more attention and has developed rapidlyin recent years.

Typically, the proton exchange membrane fuel cell includes a number ofseparated fuel cell work units. Each work unit includes a fuel cellmembrane electrode assembly (MEA), flow field plates (FFP), currentcollectors plate (CCP), as well as related support equipment, such asblowers, valves, and pipelines. The membrane electrode assemblygenerally includes a proton exchange membrane, and an anode electrodeand a cathode electrode. The proton exchange membrane is sandwichedbetween the anode electrode and the cathode electrode to form a planarsandwich structure. However, the planar sandwich structure has arelative small contacting surface with fuel and low energy conversionefficiency.

What is needed, therefore, is to provide fuel cells for solving theproblem discussed above.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations of the present technology will now be described, by wayof example only, with reference to the attached figures, wherein:

FIG. 1 is a schematic view of one embodiment of a fuel cell module.

FIG. 2 is a schematic view of one embodiment of a container of the fuelcell module of FIG. 1.

FIG. 3 is a schematic view of one embodiment of a container.

FIG. 4 is a schematic view of one embodiment of a fuel cell module.

FIG. 5 is a schematic view of one embodiment of a fuel cell module.

FIG. 6 is a schematic view of one embodiment of a fuel cell module.

FIG. 7 is a cross-sectional view along line VII-VII of FIG. 6.

FIG. 8 is a schematic view of one embodiment of a fuel cell module.

FIG. 9 is a schematic view of one embodiment of a fuel cell module.

FIG. 10 is a schematic view of one embodiment of a fuel cell system.

FIG. 11 is a schematic view of one embodiment of a fuel cell system.

FIG. 12 is a flowchart of one embodiment of a method for making a fuelcell system.

DETAILED DESCRIPTION

It will be appreciated that for simplicity and clarity of illustration,where appropriate, reference numerals have been repeated among thedifferent figures to indicate corresponding or analogous elements. Inaddition, numerous specific details are set forth in order to provide athorough understanding of the embodiments described herein. However, itwill be understood by those of ordinary skill in the art that theembodiments described herein can be practiced without these specificdetails. In other instances, methods, procedures and components have notbeen described in detail so as not to obscure the related relevantfeature being described. The drawings are not necessarily to scale andthe proportions of certain parts may be exaggerated to better illustratedetails and features. The description is not to be considered aslimiting the scope of the embodiments described herein.

Several definitions that apply throughout this disclosure will now bepresented.

The term “coupled” is defined as connected, whether directly orindirectly through intervening components, and is not necessarilylimited to physical connections. The connection can be such that theobjects are permanently connected or releasably connected. The term“outside” refers to a region that is beyond the outermost confines of aphysical object. The term “inside” indicates that at least a portion ofa region is partially contained within a boundary formed by the object.The term “substantially” is defined to be essentially conforming to theparticular dimension, shape or other word that substantially modifies,such that the component need not be exact. For example, substantiallycylindrical means that the object resembles a cylinder, but can have oneor more deviations from a true cylinder. The term “comprising” means“including, but not necessarily limited to”; it specifically indicatesopen-ended inclusion or membership in a so-described combination, group,series and the like. It should be noted that references to “an” or “one”embodiment in this disclosure are not necessarily to the sameembodiment, and such references mean at least one.

References will now be made to the drawings to describe, in detail,various embodiments of the present fuel cell modules fuel cell systemsusing the same, and methods for making the fuel cell systems.

Referring to FIG. 1, a fuel cell module 100 of one embodiment includes acontainer 101 and a membrane electrode assembly 103 located on thecontainer 101. The membrane electrode assembly 103 comprises a protonexchange membrane 102 having two opposite surfaces, a cathode electrode104 and an anode electrode 106. The cathode electrode 104 and the anodeelectrode 106 are respectively disposed on the two opposite surfaces ofthe proton exchange membrane 102.

Referring to FIG. 2, the container 101 includes a housing 1011 and anozzle 1014. The housing 1011 defines a chamber 1016 and an opening1017. The nozzle 1014 has a first end connected to the opening 1017 anda second end opposite to the first end. The nozzle 1014 extends awayfrom the housing 1011. The chamber 1016 is communicated to outside ofthe housing 1011 through the nozzle 1014. The nozzle 1014 is configuredto input and output a reacting gas, such as oxidizing gas or fuel gas.The container 101 has a plurality of first through holes 1019 on thewall of the container 101. The membrane electrode assembly 103 isdisposed on a surface of the container 101 and covers the plurality offirst through holes 1019. The container 101 includes an outside surface1012 and an inside surface 1013 opposite to the outside surface 1012.The membrane electrode assembly 103 can be located on the outsidesurface 1012 or the inside surface 1013.

The shape of the housing 1011 can be spherical, hemispherical,cylindrical or bellows shape. The container 101 is configured to supportthe membrane electrode assembly 103 and define the chamber 1016 and theplurality of first through holes 1019. The plurality of first throughholes 1019 allows the reacting gas in the container 101 diffuse to themembrane electrode assembly 103. The maximum diameter of the chamber1016 is greater than the maximum diameter of the nozzle 1014. The ratiobetween the maximum diameter of the chamber 1016 and the maximumdiameter of the nozzle 1014 can be in a range from about 1.5:1 to about100:1.

In one embodiment, the ratio is in a range from about 5:1 to about 50:1.The container 101 can be made of rigid materials such as metal, ceramic,glass, quartz, diamond, plastic or any other suitable material. In oneembodiment, the container 101 is a hollow copper sphere, both thehousing 1011 and the nozzle 1014 have the first through holes 1019thereon, and the membrane electrode assembly 103 is located on outsidesurface 1012 of the container 101 and covers entire outside surface1012. The cathode electrode 104 is in direct contact with and coversentire outside surface 1012. The proton exchange membrane 102 coversentire cathode electrode 104. The anode electrode 106 covers entireproton exchange membrane 102. Alternatively, when the membrane electrodeassembly 103 is fixed on the outside surface 1012, the anode electrode106 can be in direct contact with the outside surface 1012.

Referring to FIG. 3, in another embodiment, the housing 1011 is abellows made of polymer. In uses, the bellows shaped housing 1011 can becontracted and stretched along the height direction so the housing 1011can input and out put reacting gas. Thus, the fuel cell system using thefuel cell module 100 does not need gas supplying and extracting device.

The proton exchange membrane 102 can be perfluorosulfonic acid,polystyrene sulfonic acid, polystyrene trifluoroacetic acid,phenol-formaldehyde resin acid, or hydrocarbons. Each of the cathodeelectrode 104 and the anode electrode 106 includes a gas diffusion layer(not shown) and catalyst (not shown) dispersed on the gas diffusionlayer. In one embodiment, each of the cathode electrode 104 and theanode electrode 106 includes a carbon nanotube layer located on theproton exchange membrane 102 and a catalyst layer located between theproton exchange membrane 102 and the carbon nanotube layer. The catalystlayer includes catalyst materials and carrier. The catalyst materialsinclude metal particles or enzymatic catalyst. The metal particles canbe platinum particles, gold particles, ruthenium particles orcombination thereof. The distribution of the metal particles is lessthan 0.5 mg/cm². The enzymatic catalyst can be oxidase, dehydrogenase orthereof. The carrier can be graphite, carbon black, carbon fiber orcarbon nanotubes.

In one embodiment, the carbon nanotube layer is a free-standingstructure and can be drawn from a carbon nanotube array. The term“free-standing structure” means that the carbon nanotube layer cansustain the weight of itself when it is hoisted by a portion thereofwithout any significant damage to its structural integrity. The carbonnanotubes of the carbon nanotube layer can be orderly arranged to forman ordered carbon nanotube structure or disorderly arranged to form adisordered carbon nanotube structure. The term ‘disordered carbonnanotube structure’ includes, but is not limited to, a structure whereinthe carbon nanotubes are arranged along many different directions, andthe aligning directions of the carbon nanotubes are random. The numberof the carbon nanotubes arranged along each different direction can bealmost the same (e.g. uniformly disordered). The disordered carbonnanotube structure can be isotropic. The carbon nanotubes in thedisordered carbon nanotube structure can be entangled with each other.The term ‘ordered carbon nanotube structure’ includes, but is notlimited to, a structure wherein the carbon nanotubes are arranged in aconsistently systematic manner, e.g., the carbon nanotubes are arrangedapproximately along a same direction and/or have two or more sectionswithin each of which the carbon nanotubes are arranged approximatelyalong a same direction (different sections can have differentdirections).

In one embodiment, the carbon nanotubes in the carbon nanotube layer arearranged to extend along the direction substantially parallel to thesurface of the carbon nanotube layer so that it is easy to obtain apattern having greater light transmission. After placement on the protonexchange membrane 102, the carbon nanotubes in the carbon nanotube layercan be arranged to extend along the direction substantially parallel tothe proton exchange membrane 102. A majority of the carbon nanotubes inthe carbon nanotube layer are arranged to extend along the samedirection. Some of the carbon nanotubes in the carbon nanotube layer arearranged to extend along a first direction, and the rest of the carbonnanotubes in the carbon nanotube layer are arranged to extend along asecond direction, substantially perpendicular to the first direction.

The carbon nanotube layer can include at least one carbon nanotube film,at least one carbon nanotube wire, or combination thereof. In oneembodiment, the carbon nanotube layer can include a single carbonnanotube film or two or more carbon nanotube films stacked together.Thus, the thickness of the carbon nanotube layer can be controlled bythe number of the stacked carbon nanotube films. The number of thestacked carbon nanotube films can be in a range from about 2 to about100. For example, the number of the stacked carbon nanotube films can be10, 30, or 50. In one embodiment, the carbon nanotube layer can includea layer of parallel and spaced carbon nanotube wires. Also, the carbonnanotube layer can include a plurality of carbon nanotube wires crossedor weaved together to form a carbon nanotube net. The distance betweentwo adjacent parallel and spaced carbon nanotube wires can be in a rangefrom about 0.1 micrometers to about 200 micrometers. In one embodiment,the distance between two adjacent parallel and spaced carbon nanotubewires is in a range from about 10 micrometers to about 100 micrometers.

In one embodiment, the carbon nanotube layer includes at least one drawncarbon nanotube film. A drawn carbon nanotube film can be drawn from acarbon nanotube array that is able to have a film drawn therefrom. Thedrawn carbon nanotube film includes a plurality of successive andoriented carbon nanotubes joined end-to-end by van der Waals attractiveforce therebetween. The drawn carbon nanotube film is a free-standingfilm. Each drawn carbon nanotube film includes a plurality ofsuccessively oriented carbon nanotube segments joined end-to-end by vander Waals attractive force therebetween. Each carbon nanotube segmentincludes a plurality of carbon nanotubes parallel to each other, andcombined by van der Waals attractive force therebetween. Some variationscan occur in the drawn carbon nanotube film. The carbon nanotubes in thedrawn carbon nanotube film are oriented along a preferred orientation.The drawn carbon nanotube film can be treated with an organic solvent toincrease the mechanical strength and toughness and reduce thecoefficient of friction of the drawn carbon nanotube film. A thicknessof the drawn carbon nanotube film can range from about 0.5 nanometers toabout 100 micrometers.

The carbon nanotube layer can include at least two stacked drawn carbonnanotube films. In other embodiments, the carbon nanotube layer caninclude two or more coplanar carbon nanotube films, and can includelayers of coplanar carbon nanotube films. Additionally, when the carbonnanotubes in the carbon nanotube film are aligned along one preferredorientation (e.g., the drawn carbon nanotube film), an angle can existbetween the orientation of carbon nanotubes in adjacent films, whetherstacked or adjacent. Adjacent carbon nanotube films can be combined byonly the van der Waals attractive force therebetween. An angle betweenthe aligned directions of the carbon nanotubes in two adjacent carbonnanotube films can range from about 0 degrees to about 90 degrees. Whenthe angle between the aligned directions of the carbon nanotubes inadjacent stacked drawn carbon nanotube films is larger than 0 degrees, aplurality of micropores is defined by the carbon nanotube layer. Thecarbon nanotube layer is shown with the aligned directions of the carbonnanotubes between adjacent stacked drawn carbon nanotube films at 90degrees. Stacking the carbon nanotube films will also add to thestructural integrity of the carbon nanotube layer.

In another embodiment, the carbon nanotube layer can include a pressedcarbon nanotube film. The pressed carbon nanotube film can be afree-standing carbon nanotube film. The carbon nanotubes in the pressedcarbon nanotube film are arranged along a same direction or arrangedalong different directions. The carbon nanotubes in the pressed carbonnanotube film can rest upon each other. Adjacent carbon nanotubes areattracted to each other and combined by van der Waals attractive force.An angle between a primary alignment direction of the carbon nanotubesand a surface of the pressed carbon nanotube film is about 0 degrees toapproximately 15 degrees. The greater the pressure applied, the smallerthe angle formed. If the carbon nanotubes in the pressed carbon nanotubefilm are arranged along different directions, the carbon nanotube layercan be isotropic.

In another embodiment, the carbon nanotube layer includes a flocculatedcarbon nanotube film. The flocculated carbon nanotube film can include aplurality of long, curved, disordered carbon nanotubes entangled witheach other. Furthermore, the flocculated carbon nanotube film can beisotropic. The carbon nanotubes can be substantially uniformly dispersedin the carbon nanotube film. Adjacent carbon nanotubes are acted upon byvan der Waals attractive force to form an entangled structure withmicropores defined therein. Sizes of the micropores can be less than 10micrometers. The porous nature of the flocculated carbon nanotube filmwill increase the specific surface area of the carbon nanotube layer.Further, due to the carbon nanotubes in the carbon nanotube layer beingentangled with each other, the carbon nanotube layer employing theflocculated carbon nanotube film has excellent durability, and can befashioned into desired shapes with a low risk to the integrity of thecarbon nanotube layer. The flocculated carbon nanotube film, in someembodiments, is free-standing due to the carbon nanotubes beingentangled and adhered together by van der Waals attractive forcetherebetween.

The carbon nanotube wire can be untwisted or twisted. Treating the drawncarbon nanotube film with a volatile organic solvent can form theuntwisted carbon nanotube wire. Specifically, the organic solvent isapplied to soak the entire surface of the drawn carbon nanotube film.During the soaking, adjacent parallel carbon nanotubes in the drawncarbon nanotube film will bundle together, due to the surface tension ofthe organic solvent as it volatilizes, and thus, the drawn carbonnanotube film will be shrunk into an untwisted carbon nanotube wire. Theuntwisted carbon nanotube wire includes a plurality of carbon nanotubessubstantially oriented along a same direction (i.e., a direction alongthe length of the untwisted carbon nanotube wire). The carbon nanotubesare substantially parallel to the axis of the untwisted carbon nanotubewire. More specifically, the untwisted carbon nanotube wire includes aplurality of successive carbon nanotube segments joined end to end byvan der Waals attractive force therebetween. Each carbon nanotubesegment includes a plurality of carbon nanotubes substantially parallelto each other, and combined by van der Waals attractive forcetherebetween. The carbon nanotube segments can vary in width, thickness,uniformity, and shape. The length of the untwisted carbon nanotube wirecan be arbitrarily set as desired. A diameter of the untwisted carbonnanotube wire ranges from about 0.5 nanometers to about 100 micrometers.

The twisted carbon nanotube wire can be formed by twisting a drawncarbon nanotube film using a mechanical force to turn the two ends ofthe drawn carbon nanotube film in opposite directions. The twistedcarbon nanotube wire includes a plurality of carbon nanotubes helicallyoriented around an axial direction of the twisted carbon nanotube wire.More specifically, the twisted carbon nanotube wire includes a pluralityof successive carbon nanotube segments joined end to end by van derWaals attractive force therebetween. Each carbon nanotube segmentincludes a plurality of carbon nanotubes parallel to each other, andcombined by van der Waals attractive force therebetween. The length ofthe carbon nanotube wire can be set as desired. A diameter of thetwisted carbon nanotube wire can be from about 0.5 nanometers to about100 micrometers. Further, the twisted carbon nanotube wire can betreated with a volatile organic solvent after being twisted to bundlethe adjacent paralleled carbon nanotubes together. The specific surfacearea of the twisted carbon nanotube wire will decrease, while thedensity and strength of the twisted carbon nanotube wire will increase.

In one embodiment, each of the cathode electrode 104 and the anodeelectrode 106 may include a carbon nanotube layer and a plurality ofcatalyst particles dispersed in the carbon nanotube to obtain a carbonnanotube composite structure. The cathode electrode 104 can be made bydepositing a plurality of metal catalyst particles on a plurality ofdrawn carbon nanotube films to form a plurality of drawn carbon nanotubefilm composites and then stacking or twisting the plurality of drawncarbon nanotube film composites. The plurality of metal catalystparticles can be deposited by chemical vapor deposition (CVD),sputtering, or plasma-assisted chemical vapor deposition. The anodeelectrode 106 can be made by immerging the carbon nanotube layer into acatalyst-containing solution to obtain a carbon nanotube compositestructure.

In one embodiment, the anode electrode 106 can be made by: step (a)functionalizing the carbon nanotube layer to form a functionalized thecarbon nanotube layer; step (b) putting the functionalized the carbonnanotube layer into the catalyst-containing solution; and step (c)drying the functionalized carbon nanotube layer to obtain a carbonnanotube composite structure.

In step (a), the functionalizing can be performed by treating the carbonnanotube layer with acid such as hydrochloric acid, sulfuric acid ornitric acid. In one embodiment, the carbon nanotube layer is put into amixture of sulfuric acid and nitric acid and treating by ultrasonic forabout 2 hours. Then, the carbon nanotube layer is put into an oxydol andtreating by ultrasonic for about 1 hour. Finally, the carbon nanotubelayer is put into a water and treating by ultrasonic till a PH value ofthe become 7.

In step (b) the catalyst-containing solution can be a solution of metalor metal-salt, or a solution of enzymatic. In one embodiment, thecatalyst-containing solution is a solution of glucose oxidase. Then, thecarbon nanotube layer is put into the solution of glucose oxidase for1˜5 days at the temperature of 4° C.

Furthermore, the fuel cell module 100 includes at least one currentcollector 108. The current collector 108 is made of conductive material,such as metal, and configured to collect and conduct electrons. Thecurrent collector 108 is located on surface of the cathode electrode 104and/or the anode electrode 106. When the container 101 is made ofconductive material, the container 101 can be used as collector. Thus,only one collector 108 is needed. In one embodiment, the container 101is a made of copper, and the current collector 108 is a copper mesh.

In use, a load 120 can be electrically connected to the cathodeelectrode 104 and the anode electrode 106. The fuel cell module 100 hasfollowing advantages. First, the membrane electrode assembly 103 islocated on the container 101 and has a curved or folded surface, thus,the membrane electrode assembly 103 can have relative large contactingsurface with fuel or reacting gas. The energy conversion efficiency ofthe membrane electrode assembly 103 is improved. Second, the container101 can be used to carry the fuel or reacting gas, and the fuel cellsystem using the fuel cell module 100 has a simple structure.

Referring to FIG. 4, a fuel cell module 200 of one embodiment includes acontainer 201, a membrane electrode assembly 203 located on thecontainer 201, a first collector 208, and a second collector 209. Themembrane electrode assembly 203 comprises a proton exchange membrane 202having two opposite surfaces, a cathode electrode 204 and an anodeelectrode 206.

The fuel cell module 200 is similar to the fuel cell module 100 aboveexcept that the container 201 is made of insulative material, and thesecond collector 209 is located between the container 201 and themembrane electrode assembly 203. The second collector 209 can be formedon the outer surface of the container 201 by bonding, coating ordeposition. In one embodiment, the second collector 209 cover entireouter surface of the container 201 and defines a plurality of secondthrough holes (not shown) corresponding to the plurality of firstthrough holes 2019. The first collector 208 cover entire outer surfaceof the membrane electrode assembly 203 and defines a plurality of thirdthrough holes (not shown) allowing the reacting gas to pass through.Both the first collector 208 and the second collector 209 is a coppermetal mesh.

Referring to FIG. 5, a fuel cell module 300 of one embodiment includes acontainer 301, a membrane electrode assembly 303 located on thecontainer 301, and a first collector 308. The membrane electrodeassembly 303 comprises a proton exchange membrane 302 having twoopposite surfaces, a cathode electrode 304 and an anode electrode 306.

The fuel cell module 300 is similar to the fuel cell module 100 aboveexcept that the membrane electrode assembly 303 is located on the innersurface of the container 301 and the first collector 308 is located onthe inner surface of the membrane electrode assembly 303. The firstcollector 308 covers entire inner surface of the membrane electrodeassembly 303 and defines a plurality of third through holes (not shown)allowing the reacting gas to pass through. In one embodiment, thecontainer 301 is a hollow copper sphere having a plurality of firstthrough holes 3019. The first collector 308 is a copper metal mesh.

Referring to FIGS. 6-7, a fuel cell module 400 of one embodimentincludes a container 401, a membrane electrode assembly 403 located onthe container 401, and a first collector 408. The membrane electrodeassembly 403 comprises a proton exchange membrane 402 having twoopposite surfaces, a cathode electrode 404 and an anode electrode 406.

The fuel cell module 400 is similar to the fuel cell module 100 aboveexcept that the container 401 further includes a baffle 405 locatedtherein. The baffle 405 is located in both the nozzle 4014 and thechamber 4016. The baffle 405 extends from the free end of the nozzle4014 in to the chamber 4016 so that the space in the nozzle 4014 and thechamber 4016 is divided in to two spaces. The baffle 405 has a firstside 4051 parallel with the free end of the nozzle 4014 and a secondside 4052 opposite to the first side 4051. The second side 4052 isspaced from the bottom inner wall of the container 401. Thus, the twospaces in the container 401 are communicated with each other at bottom.Alternatively, when the second side 4052 of the baffle 405 is in directcontact with the bottom inner wall of the container 401, the baffle 405can have a plurality of through holes. The reacting gas can be input thechamber 4016 from one side of the baffle 405 and output the chamber 4016from the other side of the baffle 405. The fuel cell module 400 canimprove the cycle efficiency of the reacting gas and the energyconversion efficiency of the membrane electrode assembly 403.

Referring to FIG. 8, a fuel cell module 500 of one embodiment includes acontainer 501, a membrane electrode assembly 503 located on thecontainer 501, and a first collector 508. The membrane electrodeassembly 503 comprises a proton exchange membrane 502 having twoopposite surfaces, a cathode electrode 504 and an anode electrode 506.

The fuel cell module 500 is similar to the fuel cell module 100 aboveexcept that the container 501 defines a first opening 5017 and a secondopening 5018 spaced from the first opening 5017; and the container 501includes a first nozzle 5014 connected to the first opening 5017 and asecond nozzle 5015 connected to the second opening 5018. The firstnozzle 5014 and the second nozzle 5015 can be parallel with each otheror form an angle less than 90 degrees. The first nozzle 5014 can be usedto input reacting gas, and the second nozzle 5015 can be used to outputreacting gas. The fuel cell module 500 can improve the cycle efficiencyof the reacting gas and the energy conversion efficiency of the membraneelectrode assembly 403.

Referring to FIG. 9, a fuel cell module 600 of one embodiment includes acontainer 601, a membrane electrode assembly 603 located on thecontainer 601, and a first collector 608. The membrane electrodeassembly 603 comprises a proton exchange membrane 602 having twoopposite surfaces, a cathode electrode 604 and an anode electrode 606.

The fuel cell module 600 is similar to the fuel cell module 500 aboveexcept that the container 601 further includes a baffle 605 located inthe chamber 6016. The first opening 6017 and the second opening 6018 arelocated on two opposite sides of the baffle 605. The baffle 605 dividesthe chamber 6016 in to a first space connected to the first nozzle 6014and a second space connected to the second nozzle 6015. The baffle 605has a side spaced from the inner wall of the container 601 so that thefirst space and the second space are communicated with each other.

Referring to FIG. 10, a fuel cell system 10 of one embodiment includes afuel cell module 100, fuel 130 and oxidizing gas 150. The fuel cellmodule 100 can also be the fuel cell modules 200, 300, 400, 500, 600.

The fuel cell module 100 is at least partially immerged in the fuel 130and configured to separate the fuel 130 and the oxidizing gas 150. Theoxidizing gas 150 is inside of the chamber 1016, and the fuel 130 isoutside of the fuel cell module 100 and surrounds the fuel cell module100. The fuel 130 can be in direct contact with the anode electrode 106or diffuse to the anode electrode 106 through the through holes of thefirst collector 108.

The depth h of the fuel cell module 100 in the fuel 130 satisfies thecondition: h<P/(ρ₁−ρ₂)g, where, P represents the maximum pressure thefuel cell module 100 can bear, ρ₁ represents the density of the fuel130, ρ₂ represents the density of the oxidizing gas 150, and g is aconstant 9.8 N/kg. When the fuel cell module 100 is immerged in the fuel130 with a depth h greater than P/(ρ₁−ρ₂)g, the pressure of the fuel 130may damage the fuel cell module 100.

The fuel 130 is not limited and can be bioethanol, methane gas orglucose solution. The fuel cell module 100 is immerged in the fuel 130and the nozzle 1014 extends out of the fuel 130 so that the fuel 130would not flow in to the chamber 1016. The oxidizing gas 150 can be pureoxygen or air containing oxygen. In one embodiment, the fuel 130 isglucose solution, and the oxidizing gas 150 is air.

Furthermore, the fuel cell system 10 can include a fixing element 160connected to the fuel cell module 100. The fixing element 160 isconfigured to fix the fuel cell module 100 in the fuel 130. The fixingelement 160 can be a sucker or hook. In one embodiment, the fixingelement 160 is a sucker in connected to the bottom of the fuel cellmodule 100. When the fuel cell module 100 is immerged in the fuel 130,the sucker can be fixed on the bottom surface of the pool 170.

When the fuel cell module 100 is in the shape as shown in FIG. 3, thefuel cell system 10 can further includes an device to contract andstretch the fuel cell module 100 so that the fuel cell module 100 canexchange gas with outside.

Referring to FIG. 11, a fuel cell system 20 of one embodiment includes afuel cell module 400, fuel 130, a gas supplying and extracting device140 and oxidizing gas 150. The fuel cell system 20 is similar to thefuel cell system 10 above except that further includes the gas supplyingand extracting device 140. The gas supplying and extracting device 140includes blower, pump and valves (not shown). The gas supplying andextracting device 140 is connected to the end of the nozzle 1014 by twopipelines 110. The baffle 405 divides the space in the nozzle 4014 andthe chamber 4016 in to two spaces. The blower of the gas supplying andextracting device 140 is connected to one of the spaces and configuredto supply the oxidizing gas 150. The pump of the gas supplying andextracting device 140 is connected to the other one of the spaces andconfigured to extract the oxidizing gas 150.

Furthermore, when the fuel cell module 400 is replaced by the fuel cellmodule 500, 600 above, the blower of the gas supplying and extractingdevice 140 can be connected to the first nozzle 5014, 6014 andconfigured to supply the oxidizing gas 150. The pump of the gassupplying and extracting device 140 can be connected to the secondnozzle 5015, 6015 and configured to extract the oxidizing gas 150.

Referring to FIG. 12, the method of making the fuel cell system 20includes following steps:

-   -   step (S10), providing the fuel cell module 400;    -   step (S20), at least partially immerging the fuel cell module        400 in the fuel 130; and    -   step (S30), supplying the oxidizing gas 150 into the chamber        4016 of the fuel cell module 400.

In step (S10), the fuel cell module 400 can also be the fuel cellmodules 100, 200, 300, 500, 600 above.

In step (S20), the fuel 130 is filled in a pool 170. The fuel 130 can bemade by placing the rotten materials, such as rotten fruit, rotten foodor rotten vegetables, in the pool 170 filed with water and decomposingthe rotten materials to form the fuel 130 in the pool 170. In oneembodiment, the fuel 130 is made by placing the rotten fruit in the pool170 filed with water and decomposing the rotten fruit to form glucosesolution in the pool 170. Thus, rotten materials can be used to produceelectric energy.

In step (S30), the nozzle 4014 can be connected to the gas supplying andextracting device 140 as shown in FIG. 10. The oxidizing gas 150 can besupplied and extracted by the gas supplying and extracting device 140.

In the working process of the fuel cell system 20, the reaction ofglucose molecule at the anode electrode 106 is as follows:glucose→gluconic acid+2H⁺+2e. The hydrogen ions generated by theabove-described reaction reach the cathode electrode 104 through theproton exchange membrane 102. At the same time, the electrons generatedby the reaction above also arrive at the cathode electrode 104 by anexternal electrical circuit. The oxygen of the oxidizing gas 150 reactswith the hydrogen ions and electrons at the cathode electrode 104 as thefollowing equation: ½O₂+2H⁺+2e→H₂O. In the electrochemical reactionprocess, the electrons form an electrical current flowing through theload 120 in the external electrical circuit.

The embodiments shown and described above are only examples. Even thoughnumerous characteristics and advantages of the present technology havebeen set forth in the foregoing description, together with details ofthe structure and function of the present disclosure, the disclosure isillustrative only, and changes may be made in the detail, including inmatters of shape, size and arrangement of the parts within theprinciples of the present disclosure up to, and including, the fullextent established by the broad general meaning of the terms used in theclaims.

Depending on the embodiment, certain of the steps of methods describedmay be removed, others may be added, and the sequence of steps may bealtered. The description and the claims drawn to a method may includesome indication in reference to certain steps. However, the indicationused is only to be viewed for identification purposes and not as asuggestion as to an order for the steps.

What is claimed is:
 1. A method for making fuel cell module, the methodcomprising: providing a container, wherein the container comprises ahousing and a nozzle, and the housing defines a plurality of throughholes, wherein the housing defines a chamber and an opening, wherein thenozzle has a first end connected to the opening and a second endopposite to the first end; and applying a membrane electrode assembly,which is flexible, on the container to form a curved membrane electrodeassembly surrounding the chamber and covering the plurality of throughholes, wherein the membrane electrode assembly comprises a protonexchange membrane having a first surface and a second surface oppositeto the first surface, a cathode electrode located on the first surfaceand an anode electrode located on the second surface.
 2. The method ofclaim 1, wherein the container further comprises a baffle located inboth the nozzle and the chamber.
 3. The method of claim 1, wherein thehousing defines a first opening and a second opening; and the containercomprises a first nozzle in connected to the first opening and a secondnozzle in connected to the second opening.
 4. The method of claim 3,wherein the container further comprises a baffle located in the chamberto divide the chamber in to a first space connected to the first nozzleand a second space connected to the second nozzle.
 5. The method ofclaim 1, wherein a ratio between a first maximum diameter of the chamberand a second maximum diameter of the nozzle is in a range from about1.5:1 to about 100:1.
 6. The method of claim 1, wherein the containercomprises rigid materials selected from the group consisting of metal,ceramic, glass, quartz, diamond and plastic.
 7. The method of claim 1,wherein a shape of the housing is spherical, hemispherical, cylindricalor bellows shape.
 8. The method of claim 1, wherein the containercomprises an outside surface and an inside surface opposite to theoutside surface; and the membrane electrode assembly is located on theinside surface.
 9. The method of claim 1, wherein the containercomprises an outside surface and an inside surface opposite to theoutside surface; and the membrane electrode assembly is located on theoutside surface.
 10. The method of claim 1, wherein the container ismade of conductive material and used as a first current collector; andthe fuel cell module further comprises a second current collector sothat the membrane electrode assembly is located between the firstcurrent collector and the second current collector.
 11. The method ofclaim 1, wherein the container is made of insulative material; furthercomprises a first current collector located between the container andthe membrane electrode assembly and a second current collector, and themembrane electrode assembly is located between the first currentcollector and the second current collector.
 12. The method of claim 1,wherein each of the cathode electrode and the anode electrode comprisesa gas diffusion layer and catalyst dispersed on the gas diffusion layer.13. The method of claim 1, wherein the membrane electrode assembly islocated on entire outside surface or entire inside surface of thehousing.
 14. The method of claim 13, wherein the membrane electrodeassembly is further located on entire outside surface or entire insidesurface of the nozzle.